ML20137A164
| ML20137A164 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 12/16/1985 |
| From: | FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML20137A160 | List: |
| References | |
| PROC-851216, NUDOCS 8601140205 | |
| Download: ML20137A164 (15) | |
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CRYSTAL RIVER UNIT 3 PROCESS CONTROL PROGRAM Approved by:
cc den / Rad Supt.
Date':
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ia Approved by:
e PRC Chairman 8601140205 860 go2 Date:
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, Approved by:
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Date:
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O"N TABLE OF CONTENTS PAGE
1.0 INTRODUCTION
1
2.0 REFERENCES
2 3.0 REGULATORY REQUIREMENTS.
3 4.0 ADMINISTRATIVE CONTROLS.
5 4.1 Responsibility / Revisions....
5 4.2 Reporting.
.......................5 4.3 Documentation...........
5 4.4 Definitions.........
5 5.0 SOLIDIFICATION.
6 5.1 System Description...........
6 5.2 Process Description.....
6 5.3 Process Control Program Testing.
8 5.3.1 Process Testing.
8 5.3.2 Test Frequency.
9 f'
5.3.3 Acceptance criteria.....
9 x
5.3.4 Corrective Action....
9 5.3.5 Reporting.....
10 6.0 DEWATERING.
10 6.1 System Description......
10 6.2 Process Description.....................
11 6.3 Dewatering Program Testing..
12 6.3.1 Sample Testing and Frequency.............
13 i.
6.3.2 Acceptance Criteria and Corrective Action.......
13 6.3.3 Reporting.......
13 7.0 SHIPPING.
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1.0 INTRODUCTION
The Process Control Program (PCP) is provided to support the implementation of the Crystal River Unit 3 Radiological Effluent Technical Specifications.
The PCP contains the methodology and boundary conditions to assure that all activities related to the solidification of radwaste are regulated and directed toward a satisfactory result.
The PCP also contains the overall guidance for the dewatering of radioactive bead resin to meet the disposal criteria of the low-level radioactive waste burial facilities.
The 'PCP is not intended to be used as an operating waste procedure.
This document satisfies the requirements of Technical Specificatic.a 3.7.13.4.
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2.0 REFERENCES
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2.1.
NUREG 0472, " Radiological Effluent Technical Specifications for PWR's" 2.2 WP
- 101,
" Packaging,
- Storing, and Shipping of Radioactive Materials' 2.3 WP 102, " Radioactive Shipments Certificates of Compliance" 2.4 WP 201, " Processing with the Nuclear Waste Demineralizer System" 2.5 WP 202, " Liner Dewatering Leg construction" t
2.6 WP 301, " Radioactive Waste Solidification" 2.7 OP 413, " Waste Drumming System
- 7. 8 OP 601B, " Secondary Resin Liner Dewatering" 2.9 SP 743, " Solidification Test Batch Verification Program" 2.10 Bartlett PCP 2.11 CNSI Bead Resin Dewatering Procedure 2.12 10 CFR 61,
" Licensing Requirements for Land Disposal of Radioactive Waste" 2.13 Crystal River Unit 3 Technical Specifications 2.14 South Carolina Department of Health and Environmental Control, Radioactive Materials License 3097, Amendment #34 i
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3.0 REGULATORY REQUIREMENTS 3.1 Technical Specifications 3.7.13.4 The solid radwaste systen shall be used in accordance with a Process Control Program to process wet radioactive wastes to meet shipping and burial ground a
requirements.
The Process Control Program shall be used to verify the solidification of at least one representative test specimen from at least every tenth batch of each 4
type of wet radioactive waste (e.g., filter sludges, spent resins, evaporator bottons, and boric acid solutions).
3.2 Technical Specification 6.14 The PCP shall be approved by the Consission prior to implementation.
2 Licensee initiated changes to the PCP:
a.
Shall be submitted to the Commission in the Semiannual Radioactive Effluent Release Report for the period in which the change (s) was made.
b.
Shall become effective upon review and acceptance by the Plant Review Committee.
3.3 Technical Specification 6.9.1.5 (d)
The Semiannual Radioactive Effluent Release Report shall include a description of any changes to the Process Control Program (PCP), the Radioactive Treatment t
Systems, the Offsite Dose Calculation Manual (ODCM), as well as a listing of new Environmental Radiological Monitoring Program dose calculation location changes identified by the land use census made during the reporting period.
3.4 10 CFR 61.56, " Waste Characteristics" (a) (2) Liquid waste must be solidified or packaged in sufficient absorbent material to absorb twice the volume of the liquid.
(a) (3) Solid waste containing liquid shall contain as little free-standing and noncorrosive liquid as reasonable, but in no case shall the-liquid exceed 1% of the volume.
(b) (2) Notwithstanding the provisions of (a)(2) and (3), liquid wastes or wastes containing liquid must be converted into a form that contains ar. little free-standing and noncorrosive liquid as is reasonably achievable, but in no case shall the liquid exceed 1% of the volume of waste when the waste is in a container designed to assure i
stability, or 0.5% of the volume of the waste for waste processed to a stable form.
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'3.5 South Carolina Department of Health and Environmental
- Control, Radioactive Material License 8097, Amendment 34.
26.A.
Unless otherwise specified in this license shall not receive any liquid radioactive waste regardless of chemical or physical form.
Solidified radioactive waste shall have no detectable free-standing liquids. For purposes of this condition, the terminology "no detectable free-standing liquids" means one-half percent (0.5%) by waste volume of noncorrosive liquids per container.
B.
In lieu of the requireuents of paragraph A above, solidified waste containing noncorrosive liquids in excess of one-half percent (0.5%)
by waste volume, and less than one percent (1.0%)
noncorrosive liquids by waste volume, may be received and disposed of in high integrity containers approved by the Department.
29.
Ion exchange resins and filter media may be received in a dewatered form for transportation and subsequent burial provided that the requirements of conditions 26 and 31 are met.
31.
Ion exchange resins and filter media containing isotopes with greater that five (5) year half-lives having a specific activity of all these isotopes of 1 microcurie per cubic centimeter or greater must be stabilized by solidification. However, in lieu of solidification, the Department will authorize disposal of these waste forms meeting the free-standing liquid requirements of Condition 26 in approved high integrity containers or other approved methods of stabilization.
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4.0 ADMINISTRATIVE CONTROLS 4.1 Responsibility / Revisions Changes to the Process Control Program (PCP) are the responsibility of the F
Chemistry and Radiation Protection Superintendent.
Technical Specification 6.14 stipulates the required approvals necessary to modify the Process Control Progran prior tc implementing any changes to the process (See :::cb m 3.2).
4.2 Reporting Changes to the PCP are submitted to the Nuclear Regulatory Commission in the next Semiannual Radioactive Effluent Release Report as per Technical Specification 6.9.1.5 (d).
Reporting of nonconformances are to be done in accordance with the applicable Plant procedures.
4.3 Documentation All documentation associated with the verification of the Process Control Program is controlled in accordance with the appropriate implementing 4
procedures.
4.4 Definitions Batch - (1)
For sampling or processing, a batch is the largest homogeneous volume of waste that has been recirculated and controlled as per the PCP.
(2) For solidification testing, a batch is taken to be a disposal container (i.e.,
55 gallon drums, etc.)
utilized in the solidification of the waste.
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5.0 SOLIDIFICATION
5.1 System Description
5.1.1 The system utilized at Crystal River Unit 3, for the solidification of wet radioactive waste, consists of a mixing station with associated piping, controls and monitoring equipment. The waste is solidified in 55 gallon drums In accordance with WP 301, " Radioactive tidste Solidification".
The waste stream is measured into the receiving 55 gallon drum while the mixer is in operation and any pretreatment chemical may be added to conform to the Process Control Program requirement for proper solidification.
The Modified j
Portland Cement (MPC-1) is added to the waste until the required ratio is reached per the PCP requirement.
The actual sequence of additions may vary i
per the process test results.
5.1.2 Resin Solidification The primary resin transferring system for solidification is controlled by OP 413, " Waste Drumming System. "
This Operation Procedure gives the valve and pump lineups, and provides an overview of the resin flow path from the spent resin tank to the shipping container and the return path of the excess water.
The resin can be recirculated in the spent. resin tank (7000 gallon capacity) using the resin slurry pump to obtain a homogenous mixture. Decant water can be added to the suction side of the pump to insure that the proper water to resin ratio is obtained for transfer to the solidification contalaer.
Resin transfer from the spent resin tank to the solidification apparatus is made using the resin slurry pump. Water is decanted before solidification and t
returned to the spent resin tank.
5.1.3 Liquid waste Solidification 4
FPC procedural guidelines concerning the transfer of liquid waste for solidi-fication are given in OP 413, " Waste Drumming System.'
This procedure gives an overview of the flow paths of liquid wastes from the various tanks to the solidification apparatus.
Liquid wastes can be stored in two concentrated boric acid storage tanks (CBAST - 7000 gallon capacity each) atA in two concentrated waste storage tanks (CWST - 7000 gallon capacity each).
The CUST's are utilized as concentrated boric acid storage tanks whenever possi-ble. Waste is transferred to the solidification apparatus utilizing the waste transfer pumps at the CBAST's or the CWST's.
5.2 Process Description The solidification system is designed to solidify radioactive waste including, boric acid waste, evaporator bottoms, ion exchange resin, sludges, oils and various solids for encapsulation and immobilization.
The waste products are solidified using the commonly available Portland I cement modified with the necessary process additives.
The Modified Portlant Cement (MPC-1) and addi-tives can be adjusted to optimize the waste to cement ratio or to perform the solidification in a specified manner.
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The reactions from cement and waste form very stable hydrates from the chemical combination of calcium, silicon, and aluminium with oxides.
The reactions are exothermic and are not readily produced unless strong alkalines are present at a pH of 11 to 12.
Other chemicals in the waste stream may inhibit or accelerate the set.
These chemicals must be controlled by modifying the additives to ensure a controlled, homogenous, free-standing monolith, dry, and with the final product able to resist penetration when probed by a firm object.
Ac the conclusion of each transfer of waste, the piping forward of the recirculation line must be flushed.
This is necessary to reduce personnel exposure, plugging of the pipes, and pipe corrosion.
5.2.1 Sampling The waste tanks should be recirculated to obtain a representative, homogenous sample.
A volume of waste is considered to be homogenous when three (3) tank volumes have been recirculated on an isolated batch of material.
The waste tanks should be maintained on recirculation until sampling and solidification are cc.plete.
If the previously analyzed waste tanks receive additional material, the new mixture must be recirculated, resampled, and reanalyzed.
The following samples and analyses are necessary to prepare waste for solidification and disposal:
- Sample for isotopic analysis and curie content Sample for chemistry parameters and PCP test solidifications 5.2.2 Chemistry of Waste Products Chemistry analyses are necessary for successful solidification since the process can be dependent on specific ions, pH, and oil.
Cement solidification of wastes requires the consideration of the parameters listed below:
Chlorides Oils Boron Organic Solvents Ammonia Decontamination Solutions Soap / Detergents Neutralizer Compounds Waste chemistry should be collected and analyzed as per section 5.2.1.
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.c 5.2.3 Waste to Cement Ratio The vaste to cement ratio will vary due to the chemistry of the waste stream.
The approximate ratio of solidification media to waste is listed in the following table:
Binder / Media Waste Type Waste: Media Cement Evaporator Bottoms 2: 1 Cement Ion Exchange Resins 2.5 : 1 Cement oil 2: 1 5.2.4 Cure Time The cure time for the solidification of waste will vary depending on the type waste being processed.
The completion of the solidification process may be verified by monitoring the initial curing process temperature rise and fall; thus indicating a safe, capable product. As an example, the initial cure time for a test sample is approximately 30 minutes to 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />, and for full scale solidification approximately 6 to 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.
'5.3 Process Control Program Testing i
5.3.1 Process Testing 5.3.1.1 Initial Process Testing Prior tc solidification, each batch of homogenous waste is to be tested to assure that proper solidification of the waste will result.
The process tests are to include all additives and the appropriate Modified Portland Cement (MPC-1) volumes mixed and adjusted as described below:
Additive volume and constituents measured and recorded Modified Portland cement volumes measured and recorded
- Waste volume measured and recorded
- Waste pH adjusted to within 10.5 to 11.5 range and recorded
- MPC-1 addition with mixing
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- Appropriate cure time (30 minutes or more)
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-- Testing of sample as per Section 5.3.3 and results recorded Several tests should be performed on the same waste stream, varying the additives and MPC-1 mixes in order to develop the best end product.
Evaluation of the test specimen for waste to binder ratio, free-standing water and maxinua hardness should be made to determine the appropriate matrix. The selected test sample should be repeated for verification of performance. Full scale solidification would commence following the evaluation of sample tests against the Acceptance Criteria of Section 5.3.3.
5.3.1.2 Solidification Testing i
During full scale solidification, a representative sample of waste is to be solidified as per the PCP requirements at the frequency specified in Section 5.3.2.2.
The test specimen is to be evaluated against the Acceptance criteria O
l of Section 5.3.3.
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.5.3.2 Test Frequency 5.3.2.1 Process Test Frequency A process test solidification shall be made prior to full scale solidification to determine ratios and additives as per Section 5.3.1.1.
5.3.2.2 Solidification Test Frequency The. PCP shall be used to verify the solidification of at least one (1) representative. test specimen from every tenth batch of each type of wet radioactive waste.
5.3.3 Acceptance Criteria SP_ 743, " Solidification Test Batch Verification Prograa," stipulates the activities and documentation necessary to verify acceptance of solidified waste.
f The solidified waste acceptance criteria is verified by:
a.
Visually inspecting for defects in the structure, b.
Uniformity in color and density.
c.
No free-standing liquid (<0.5% of total waste volume).
d.
Free-standing monolith, e.
After 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> from solidification, the final cured product shall resist penetration when probed 3y hand with a spatula or firm object (>50 psi).
If any portion of the specimen fails to pass the Acceptance Criteria, the applicable actions of Section 5.3.4 aust be met.
5.3.4 Corrective Action a.
If the initial test specimen from a batch of waste fails to verify solidification, representative test specimens from each consecutive batch of the same type of wet waste shall be collected and tested until at least 3 consecutive initial test specimens demonstrate solidification.
The process and/or additives shall be modified as rec' tired, as provided in i.
Section 4.1, to assure solidification of subsequent Mtches of waste.
- b. If any test specimen fails to verify solidification, the solidification of the batch under test shall be suspended until such time as additional test specimens can be obtained, alternate solidification parameters can be determined in accordance with the Process Control Program, and a subsequent test verifies solidification.
Solidification of the batch may then be resumed using the alternative solidification parameters determined by the Process Control Program.
i' c With installed equipment incapable of meeting Technical Specification 3.7.13.4 or declared inoperable, restore the equipment to operate status or provide for contract capability to process wastes as necessary te satisfy all applicable transportation and disposal requirements.
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5.3.5 Reporting O
The reporting of nonconforming results of the solidification process is to be done in accordance with Section 4.2.
6.0 DEWATERING
6.1 System Description
The bead resin dewatering systems utilized at Crystal River Unit 3 are i
comprised of two separate processes.
One for the secondary cycle condensate resin and the other for primary or radioactive waste ion exchange resin.
Secondary Cycle Condensate Resin Dewatering System This system is utilized to dewater bead resin from the secondary cycle condensate desineralizer system in accordance with OP 601 (B). The condensate desineralizer system is comprised of holding vessels that provide full flow desineralization of the secondary cycle water.
The resin in each demineralizer vessel, once expended, is transferred to a shipping container for dewatering and disposal.
The expended resin is transferred into a shipping container that has been prepared with dewatering lines, and a tube called a "QC tube" for verification of dewatering performance.
The dewatering lines are designed to remove the a
water from the bottom of the container via a network of tubes that are connected to a center dewatering line.
The QC tube is a separate line that terminates at the bottom edge of the container.
The dewatering manifold and QC tube are constructed of corrosion resistant material and of sufficient length to reach the bottom of the container, and extend through the access port at the top.
The bottom legs of the manifold are modified (slits, holes, etc.) to allow flow to enter the entire length of the pipe.
The modified pipes are then covered with a filter material with a mesh size that precludes the entry of resin beads.
The piping is connected together and to a vertical line in such a way as to provide adequate coverage of the container floor. The openings in the manifold legs must face the floor of the container.
The QC tube is secured along the center post of the i
manifold and angled across the bottom legs to a distance equal of the radius or corner measurement of the container.
The outside of the container is marked to locate the QC tube end point after the dewatering unit is outlined in Op 601 (C), " Liner Dewatering Leg Construction."
The vacuum source for the dewatering is supplied by a portable vacuum pump.
The overpressure of the containers is accomplished using station / instrument air or a portable air pump.
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Primary and Radwaste Resin Dewatering Systems This system is utilized to dewater bead resin from the primary plant clean up system or the radioactive waste processing system. The primary plant clean up resin is utilized internal to the reactor water clean up system and must be transferred to a shipping container prior to dewatering.
The radwaste procersing resin may be housed in its own shipping container or transferred for dewatering.
The expended ion exchange rerin is transferred, if necessary into a container to be used for shipment and bt. rial by means of resin transfer pumps. Prior to resin addition, the receiving container is outfitted with dewatering devices that allow for the removal of tree-standing water.
A primary dewatering tube with its distribution legs is located in the center of the container. A much smaller secondary dewatering line, if available is also connected to the devatering header for removal of the final water volumes and verification of dewatering criteria.
The disposal container has level alaras to monitor filling operations, and visual observations are possible.
All lines are flushed to the container following any resin transfer for dewatering.
The dewatering process is performed in accordance with OP 413, " Waste Drunning Systen." The vacuum source for dewatering is supplied by a portable pump.
6.2 Process Description Secondary cycle condensate Resin Dewatering System The shipping container is filled to the proper level with the resin slurry in accordance with OP 601.
Utilizing the dewatering line in the container, the resin is initially dewatered as per Op 601.
The remaining water is removed from the container via vacuum pumps and overpressurization as follows:
i a.
The container is pressurized (~2 psig) and dewatered utilizing the dewatering line for a minimum of 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />.
b.
The container is depressurized and allowed to settle for at least I hour.
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c.
Steps a & b are repeated two additional times with dewatering being performed for a minimum of 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> instead of 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />.
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d.
The container is then blown down wit's a slight overpressure of compressed air (~3 psig) for a mininua of 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />.
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The container is allowed to settle for a minimum of I hour.
f.
The blowdown is repeated two additional times for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> each time.
g.
The container is then titled on a support frame and allowed to settle for at least 1 hours1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br />.
i h.
The QC tube is connected to a vacuum pump and run for at least 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br />.
Hourly volumes are measured and compared against the acceptance criteria j
in OP 601(B).
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If the acceptance criteria is net, dewatering is complete.
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If the acceptance criteria is not met, the dewatering process must be repeated.
If the acceptance criteria in Section 6.3.2 is set, the container is sealed, labeled, and placed in a storage area for shipment.
Primary or Radwaste Resin Dewatering Systen The shipping container is filled to the proper level with the resin slurry.
Utilizing the primary dewatering lines in the container, the water is removed from the vessel via a vacuun pump as follows:
a.
The first pump down utilizes the primary dewatering line.
(8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> minimum and record times of pumping.)
b.
A settling period follows.
(8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> minimum.)
c.
A second pump down utilizing the primary dewatering line is performed.
(8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> mininua and record times of pumping.)
d.
Another settling period follows.
(8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> minimum.)
e.
A third pump down utilizing the secondary dewatering line, if available, is accomplished.
(8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> minimum and record pump times.)
O f.
The remaining volume of water is collected and measured as per Section 6.3.1.
g.
An evaluation of the volume of water collected against the acceptance criteria of Section 6.3.2 is performed.
h.
If the acceptance criteria is set, dewatering is complete.
1.
If the acceptance criteria is not met, the vessel is allowed to settle for a minimum of 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> and the third pump down process is repeated until the acceptance criteria is satisfied.
Once the acceptance criteria of Section 6.3.2 is set, the vessel is sealed, labeled and stored for shipment offsite.
6.3 Dewatering Program Testing 6.3.1 Sample Testing and Frequency Following the dewatering process, the water is measured on a volume basis for coararison against the acceptance criteria.
Numerous measurements / evaluations may be necessary based on the results of the comparison against the acceptance criteria.
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..a 6.3.2 Acceptance Criteria and Corrective Action OP 601(B),
" Secondary Resin Liner Dewatering," and WP stipulates the activities and documentation necessary to verify acceptance of dewatering criteria.
The dewatered resin must meet the conditions applicable to the container used for disposal as follows.
6.3.2.1 1% Free-Standing Water or Less (High Integrity Container only)
The acceptance criteria for dewatered resins in High Integrity Containers j
(HIC) is 1% free-standing water or less (by volume) as specified in Section 3.5, Items 29, 31 and 26 (B).
6.3.2.2 0.5% Free-Standing Water or Less (Non-High Integrity Centainers)
The acceptance criteria for dewatered resins in containers that do not meet the requirements for High Integrity Containers (HIC) is 0.5% free-standing water or less (by volume) as specified in Section 3.5, Items 29 and 26 (A).
6.3.3 Reporting The reporting of nonconforming results of the dewatering process is to be done in accordance with Section 4.2.
7.0 SHIPPING The shipment of solidified and dewatered radioactive waste is controlled by WP O
101, " Packaging, Storing and Shipping of Radioactive Materials."
Activities and documentation of radioactive shipments is maintained under this procedure.
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